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Competition rules for 2018

Copies of the rules

For copies of the rules, with the appendices and team registration pages, email Peter Teertstra.

1. Electrical Vehicle Challenge

Students, with the assistance of their technology teachers or other mentors, design and build battery powered vehicles capable of carrying a driver the maximum distance on a single charge. The Electric Vehicle (EV) Challenge consists of two endurance races: a 12 V race and a 24 V race.

1.1 Mission Statement

The Waterloo Electric Vehicle Challenge mission statement is to:

Provide an accessible enrichment program. The event organizers seeks to reduce barriers to entry and keep a level playing field for all teams, regardless of their financial resources.

Provide a safe event for teams to celebrate their success. The EV Challenge makes every effort to ensure its events are as safe as possible for teams.

Support the growth of the EV Challenge community in Ontario. The formation of new teams is actively encouraged, with the responsibility for mentoring and promoting new teams shared between the event organizers and established teams. The EV Challenge will actively seek financial support for new teams.

2. Registration

2.1 Online Registration

Teams must complete an online registration to compete at the Waterloo EV Challenge. This is done on the EV Challenge website and must be completed at least two weeks prior to the competition date. There is no cost to register.

2.2 Registration Limit

In 2018 there will be two 12 V heat races and one 24 V race. The winner of the 12 V race will be based on the number of laps and elapsed times from both heat races. There is a limit of one (1) entry per team per race or per heat race, for a total of three (3) entries in the competition, as follows

A team may bring three cars to the competition; entering one car in one of the 12 V heat races (one entry), one car in the other 12 V heat race (one entry), and the third car in the 24V race (one entry).

A team may race two cars; entering one car in one of the 12 V heat races and in the 24 V race (two entries) and the other car in the second 12 V heat race (one entry).

A team may race two cars; entering one car in one of the 12 V heat races (one entry) and the other car in the second 12 V heat race (one entry)

A team may race one car in one of the 12 V heat races (one entry) and race the same car in the 24 V race (one entry)

A team may race one car in the 24 V race (one entry)

A team may race one car in one of the 12 V heat races (one entry) **Rookie teams that have received an EV Kit are expected to register for one 12 V heat race only.

2.3 On-site registration

In addition to the online registration, teams must complete an on-site registration between 8 and 9 am on Saturday or, for local teams, 4 to 6 pm Friday. Teams are expected to provide the following documents during this time:

Completed Team Registration Form including the names of all students and teacher/advisors that are attending the event and the names of all drivers

Completed Participant Information Sheet form for all students and teacher/advisors that are attending the event.

A completed Safety Inspection Checklist for each vehicle.

A signed Construction Responsibility Waiver for each team.

Drivers for the 24 volt race need to show a valid driver’s license.

See the appendix for copies of these forms.

A certificate of insurance will be required for any team that is not affiliated with a Ontario Secondary School or an Ontario Catholic Secondary School. This includes college teams and community teams.

2.4 Early Load-in & Registration

Teams are permitted to load in on Friday from 4PM to 6PM. During this time, teams may also complete their safety inspections. On-site registration and award judging will wait until Saturday morning. Secure storage for vehicles and trailers will be provided for all teams.

3. Competition Classes

There are two different classes within the competition; one for high school students and
one for college students. Each class builds their vehicle and competes according to a
different set of guidelines, as follows:

3.1 High School Team

A high school team is defined as a group of students that are currently enrolled in high school working together to build and compete with a vehicle. A team does not have to be associated with a particular school, but must have a teacher, parent or mentor acting as a supervisor for the team.

High school teams may enter the same car year into the competition that was raced in previous years. There is currently no cost limitations imposed on high school teams. All vehicles must be designed and built according to the Vehicle Design Rules.

3.2 College Team

A college team is defined as a group of students that are currently enrolled in a college program working together to build and compete with a vehicle. A college team must be associated with a particular school and must have a teacher acting as a supervisor for the team.

All vehicles built and raced by college teams must be designed and built according to the Vehicle Design Rules. The following additional rules are added to the competition for college teams.

3.2.1 A car entering the college division race must have a new frame each year. The
design of the frame can be similar but it is expected that some level of
improvements will be made to the design. The frame must be newly fabricated
every year. Components of the car other than the frame can be reused but cost
of retail parts must be included in the total price of car.

3.2.2 The races will be named a one battery race or a two battery race. How the power
supply units are used are up to the teams entering the race. The 12 V race for
the High Schools will be the one battery race for the Colleges and the 24 V race
will be the two battery race. Teams may boost voltage or run batteries in parallel
if they wish. Batteries cannot be exchanged or recharged during the race and the
same batteries must be in the car for the entire race. Two batteries must be in
the car at all times for the two battery race.

3.2.3 The battery used must be the Optima yellow top SC35DA. This is so each team
is using the same power source.

3.2.4 All electrical components must be sized and protected according to safe
electrical standards and codes.

3.2.5 The total cost of building the car must not exceed six thousand dollars ($6,000
CND), this is to include donations and sponsorship materials and parts. Retail
costs of parts recycled from a previous vehicle or donated must be included in
the total costs of the build. If using wheels from last year the current retail cost of
the wheels must be part of the $6,000. The cost of the batteries is not included in
this total cost. Travel and helmet expenses are not included in this cost.

3.2.6 As part of the registration and safety inspections teams must provide
documentation for the car including mechanical drawings, electrical schematics
and cost spread sheets. A separate award for team documentation will be
awarded to the team judged to have the best presentation for their car.

4. Vehicle Design Rules

All vehicles competing in the EV Challenge must conform to the following design guidelines. (These have been taken primarily from the Electrathon America design guidelines and adapted for use in the EV Challenge)

4.1 Dimensions

The distance between the tires must be at least 0.60 m, center to center.

The vehicle may be no wider than 1.2 m at its widest part.

The maximum vehicle length is 3.5 m.

4.2 Configuration

Vehicles must be three- or four-wheeled. All wheels must be load-bearing and must remain in contact with the ground at all times.

4.3 Driver Position

4.3.1 The driver must be in a sitting position. A kneeling or head-first position is not permitted.

4.3.2 Arms and legs must remain within the vehicle body structure during normal operation of the vehicle.

4.3.3 The driver must be able to exit the car independently in less than 1 minute.

4.4 Frame

4.4.1 All vehicles must have frame members that protect the driver in the event of a collision from any direction. This includes having the frame extend beyond the driver's feet and having adequate side protection for the driver.

4.4.2 Frames mst be constructed using steel or aluminum. Members may be joined by welding or with bolts. Non-structural frame members may be constructed using other materials, including wood, plastic, composites, etc.

4.5 Roll Bar

There must be a roll bar that extends 50 mm over the top of the helmet of the tallest driver, and protect them throughout their full range of motion. It must be constructed so that, in the event of a roll-over, the driver’s head is fully protected.

The roll bar must be made from steel or aluminum, welded or bolted construction.

The roll bar must be triangulated with at least three legs or panel equivalent.

4.6 Vehicle Body

The vehicle body is only required to be structurally strong if the frame does not provide adequate protection from an impact. If the frame is not sufficient, then the body must be constructed to protect the driver in the event of an impact.

The body must have a floor to prevent the driver from contacting the ground.

The driver’s legs and feet must be enclosed to prevent them from leaving the vehicle in the event of an accident.

4.7 Stability

The vehicle must be stable at rest, while cornering, braking, and at top speed.

Leaning vehicles are not permitted.

4.8 Steering

The vehicle’s steering must allow for a minimum turning radius of 5 m.

4.9 Brakes & axles

At least two wheels must have brakes.

Brakes must be fitted to two wheels of the same axle – either two on the front or two on the back, depending on vehicle construction.

The two brakes must have separate actuation cables. If both brakes are actuated by a single hand or foot lever, then both cables should be attached to the lever.

The vehicle must not roll if the brakes are applied.

Axles supported at both ends must have a diameter of at least 10 mm.

Axles supported only on one end must have a diameter of at least 12 mm.

Safety wire or cotter pins must be used to secure all wheel axle nuts. Nylon lock nuts and double nuts alone are not acceptable.

4.10 Tires

Tires must be inflatable.

Vehicles should be designed with at least 40 mm ground clearance.

The driver must not be in a position to come in contact with the tires, wheels, or spokes.

4.11 Batteries

The required battery for both the 12 V heat races and 24 V race is the Optima yellow top SC35DA. No other battery may be used in the competition.

Batteries must not be modified or heated.

Batteries must be securely attached to the vehicle in such a manner that they are protected from a roll-over or impact, and, in the event of an accident, will not leave the vehicle. Examples include a metal bracket or a ratchet strap.

4.12 Electrical system

A fuse or circuit breaker is required in any electrical circuit between the battery and any electrical device.

All fuses or circuit breakers should be mounted as close as practically possible to the source of power.

All fuses or breakers should be sized to protect the wiring to which they are connected.

4.13 Isolation Switch

An isolation (kill switch) is required on all vehicles. This switch must have a break current rating that exceeds the maximum current draw of the vehicle.

The switch must be located in the main positive power cable, between the battery and any motor controller.

The driver must be able to actuate the switch while in driving position, without reaching outside the vehicle. Race officials must be able to actuate the switch from outside the vehicle without reaching in. Two separate switches may be used.

The switch must be in a colour contrasting the rest of the vehicle, preferably red.

A circuit breaker may be used as the isolation switch.

Wiring must be well-insulated and securely attached to the frame or body. All wiring must be visible for inspection for the entire length of the wiring runs. All wiring must be kept free from moving parts and protected from chafing.

Wiring that passes through a hole with sharp edges or through sheet metal must be protected by an insulating grommet or other suitable device.

Terminals must be secured so they will not come loose or short out during a competition.

No part of the system may use the vehicle frame as a conductor. The frame must not be grounded.

4.14 Wiring

Wiring must be well-insulated and securely attached to the frame or body. All wiring must be visible for inspection for the entire length of the wiring runs. All wiring must be kept free from moving parts and protected from chafing.

Wiring that passes through a hole with sharp edges or through sheet metal must be protected by an insulating grommet or other suitable device.

Terminals must be secured so they will not come loose or short out during a competition.

No part of the system may use the vehicle frame as a conductor. The frame must not be grounded.

4.15 Motor transmission

All vehicles must only be powered by electric motors.

All gears, chains, and sprockets must be covered. Strong material i.e. steel, aluminum, or Lexan must be used in constructing the guards. The guards should cover all moving parts in such a way that a finger or hand cannot reach them.

4.16 Motor controller

Any type of power controller is allowed.

Power to the motor must be controlled by the driver, and turn off automatically when the driver releases the accelerator (‘dead man’ cut-off).

Remote control of a vehicle is not permitted.

Computers are permitted on the vehicle if they present information only or collect data. The driver must have complete manual control of the vehicle.

4.17 Mirrors

Vehicles must be equipped with at least 8 square inches of usable mirror surface area. Mirrors are required on both sides of the vehicle

The mirrors must allow the driver to see clearly to the rear on both sides of the vehicle.

Electronic sensing devices, such as video cameras and monitors, may not be used as a substitute for rear-view mirrors.

4.18 Safety belts

All vehicles must be equipped with a five-point automotive seat belt system.

Seat belts must be mounted to a structural point at least 3 inches below the top of the driver’s waist.

The shoulder harness must be attached to a structural point at least 3 inches below the driver’s shoulder.

4.19 Helmets

All drivers must wear a helmet that is DOT approved for motorcycles. Eye protection - shield, goggles or safety glasses - is required at all times.

Vehicles must display numbers at least six inches in height using contrasting colours to the vehicle.

Ontario numbers are indexed at uwaterloo.ca/evchallenge/numbers. Teams should use this resource to register new numbers in advance of competition and ensure their numbers do not conflict other teams’.

If a team has been inactive for three years, their numbers may be used by other teams and will be removed from the registry.

A team will own all numbers they have registered so long as the team is active. Old numbers that are no longer used by an active may be requested by contacting the team.

The number must be in contrasting colours to the vehicle. The registered numbers must be the only numbers visible on the vehicle.

5. Safety

Pursuant to the mission of the EV Challenge, safety is of utmost importance during the event. Any cars or drivers deemed to be unsafe will not be allowed to participate in the race. These decisions will be made by the race organizers, the Head Marshal and the Lead Safety Inspector.

5.1 Safety inspection

The safety inspection will verify that the car has been constructed according to the Vehicle Design Rules and that the driver has the required safety equipment. If a car fails the safety inspection, that car will not be allowed to compete. All rulings by the judges are final. If a car is repaired, a second safety inspection will be conducted. The race will not be delayed for this process.

Teams located near the University of Waterloo are encouraged to bring their vehicles for safety inspection on Friday afternoon. Teams located further away will have their vehicle inspected on Saturday morning.

Prior to the competition, the team’s teacher / advisor will complete the Safety Inspection Checklist form (found in the Appendix) by initialing each line to confirm the team has met the requirements. The team will present the completed form at the on-site event registration and the judge will refer to the form during inspection of the vehicle. The requirements to pass the stationary inspection are as follows.

The vehicle must have a minimum of three road wheels. All wheels must be in contact with the ground at all times. Vehicle must be inherently stable at rest and in operation.

The frame must be fabricated in such a way to protect the driver in a collision. The design and fabrication must be structurally sound.

Mirrors are required on both sides of the vehicle to permit the driver a clear view behind.

A five-point safety harness is properly mounted.

All wiring must be visible for inspection for the entire length of the wiring runs. All wiring must be insulated and neatly secured and terminated. Wiring must be sized to have sufficient capacity.

Batteries must be firmly secured to the chassis with a metal strap, a ratchet strap, or are otherwise strongly secured. In the event of a collision, the battery must not move.

There must be an Emergency Power Off switch on the vehicle, accessible to the driver and emergency workers outside the car.

Brakes must be fitted on two wheels of the same axle. Each of the brakes on the two wheels must have a separate actuation cable. If both cables are to be actuated by a single lever then both cables are to be mounted to a common lever. The vehicle must not roll if pushed when the brakes are applied.

Cotter pins or safety wire must be used to secure all wheel axle nuts.

All chains, sprockets, belts or pulleys in the vehicle drivetrain must be safeguarded to prevent injury to the driver or any member of the team. Strong material i.e. steel, aluminum, or Lexan must be used in constructing the guards. The guards should cover all moving parts in such a way that a finger or hand cannot reach them.

The vehicle must have a steel or aluminum roll bar mounted to the frame in such a manner as to prevent collapsing or breaking. The bar must be at least two inches above the top of the tallest driver's helmet when seated in race position. The roll bar must be braced either forward or rearward to the frame of the vehicle. It must provide protection for the driver’s head throughout the full range of possible movement.

The driver must wear a helmet that is DOT approved for motorcycles. Eye protection - shield, goggles or safety glasses - is required at all times.

The driver must be able to exit the car independently in less than 1 minute

Please note that this not a complete set of rules to be followed and additional inspection items may be applied as necessary. These rules represent the most significant hazards teams will face. For a full set of rules, see Section 4 Vehicle Design Guidelines.

5.2 Event safety

During the event, extensive arrangements are made to promote the safety of all participants. These include:

Dedicated first-aid trained personnel will be on-site throughout the event.

A fire extinguisher will be on-site with a trained operator.

No less than eight (8) marshals will be present to monitor the race and respond to emergencies. Race organizers and marshals will be in continual radio communication regrading overall event progress and safety. Marshals will use horns and other visual aids to stop the race when conditions merit.

Race marshals and other track workers will wear high-visibility vests.

The race area will be secured with various levels of crowd control/barricades. For any area where there is the potential for a vehicle to leave the race course and cause an injury, a metal barricade will be used. A combination of wood barricades and barricade tape will be used to secure other areas. Volunteers will be stationed around the course to provide a secure perimeter at all times.

6. Race Rules

6.1 Race schedule

The 12 volt class race will be 60 minutes in duration and the 24 volt class race will be 75 minutes in duration. Each race will end when the time is complete or when none of the cars are able to continue. Time is kept by the race organizers and will broadcast to teams through a public webcast.

Each team must make two pit stops during the first 60 minutes of the race (both 12 volt and 24 volt classes) to change the driver of the car, as follows.

1. 12 V drivers must be team members. They must be of high school age.

2. 24 V drivers must be team members and have a valid G1 license, or equivalent.

3. Teams competing in multiple races (12 V heats and 24 V) must register and use a minimum number of qualified drivers as follows:

A team with one race entry must register and use at least 2 qualified drivers

A team with two race entries must register and use at least 4 qualified drivers

A team with three race entries must register and use at least 6 qualified drivers

A driver cannot drive more than one event. (i.e. A driver cannot drive in both 12v races, a driver that races the 12v event cannot drive in the 24v race

4. At least two different drivers must be used by each team during each race (12 and 24 volt). It is expected that each driver will complete approximately 1/3 of the scheduled race duration.

5. If a team chooses to have only two drivers, they must still perform two driver changes during the race. The driver who is re-entering the race must completely exit the car and place both feet on the ground before re-entering the car.

6. Each driver must complete one full lap before beginning another driver change.

7. Teams are allowed to change the driver if they have stopped in the pit area to repair a mechanical problem.

8. Teachers/advisors must disclose hearing or uncorrected vision impairments, including colour-blindness (particularly red/green), of their drivers to the organizers at least one week prior to the race. Race controls (i.e., flags) are colour-coded and this can present a safety hazard if unaddressed. Every effort will be made to allow the driver to participate, if participation can be done safely.

6.4 Cell phones & communication devices

Compliance with the following sections may require additional design changes to the vehicle. Communication devices must not distract the driver.

The race organizers, in cooperation with the Head Marshal and the Lead Safety Inspector, has the right and authority to remove from the competition any driver, vehicle or team that has demonstrated a lack of respect for the rules of the competition or poses a safety risk for themselves or others.

6.6 Scoring

The finishing order for each race will be determined based on the number of laps that each car completed during the scheduled time. Scoring will be performed as follows.

Assignment of transponder. Each car will have an assigned transponder that will be used to track its progress during the race. Every time the car crosses the finish line, the scoring system will add one to the number of completed laps for that car.

End of race. When the scheduled race time is complete, the checkered flag will be shown to all cars as they cross the finish line. The scoring system will log the finishing order based on the final number of laps that each car completed and their relative finishing position.

12 volt heat races. The results from the two 12 V heat races will be combined to find the overall winners for the 12 V class, based on final number of laps, relative finishing order and total elapsed time for each vehicle.

Last lap in the event of power failure. If a car runs out of electrical power and it pulls off the track into a safe area, it will only be scored based on the number of laps it has completed and not the lap that it is on.

Mounting The Transponder will be provided at the race and should be attached to the outside of the body shell in an area near the front of the vehicle where it can point upwards. All teams are required to prepare their vehicle for the transponder as follows:

(1) Location. Identify the location where the transponder will be located. This should be a flat area near the front of the vehicle where the transponder can “see” the scoring loop above it without obstruction. The transponder must be attached using the Velcro tabs provided.

(2) Power. The transponder must be powered by one of the vehicles 12 volt batteries directly – not wired through the main shutoff switch. It may not be powered using a separate battery pack. It is the team’s responsibility to provide wiring from the battery to the transponder and attach to the connector provided to the team prior to the competition.

6. Transponder failure. In the case of a transponder failure during the race, the race will be stopped with a red flag and the situation corrected as follows:

(1) Transponder function will be checked, and correct 12 volt power verified.

(2) The transponder will be replaced with another transponder and the race will be restarted.

(3) If the transponder still is not functioning, the car will be manually scored for the remainder of the race.

7. Awards

The EV Challenge provides awards as follows

7.1 Race Awards (High School)

Awards for 1st, 2nd and 3rd place for both the 12 V and 24 V races are presented to the schools with teams having the most total laps, as follows:

(1) 1st place will be awarded to the school with the team that completed the most laps according to the electronic scoring system.
(2) 2nd place will be awarded the next, different school with the team that completed the next highest number of laps according to the electronic scoring system.
(3) 3rd place will be awarded the next, different school with the team that completed the next highest number of laps according to the electronic scoring system.

7.2 Interstate Batteries Rookie Team Award (High School)

The Interstate Batteries Rookie Team Award is given to the team competing for the first time at the EV Challenge whose vehicle scored the most number of laps in one of the 12 V heat races.

7.3 Dennis Weishar Engineering Design Award (High School)

The Engineering Design Award will be presented to the school that demonstrates the best overall design innovation, use of engineering calculations, and/or design for ease of assembly, maintenance, ergonomics and safety in their competition vehicles.

The Engineering Design Award is judged in two parts: an engineering report submitted one week prior to the competition, and an interview with qualified teams during the time between registration and the first race, approximately 8:00AM - 9:45AM. Only teams that submit an engineering report will qualify for the award, and interviews will only be conducted with these teams.

7.4 Toyota Fabrication & Manufacturing Award (High School)

The Toyota Fabrication & Manufacturing Award will be presented to the school that demonstrates the best examples of manufacturing and fabrication in the vehicles that their team brings to the competition.

To qualify for this award, teams must be able to provide examples of manufacturing and fabrication that have been completed in the current year. These examples can include new vehicle or new systems (powertrain, steering, etc.) adapted to existing vehicles.

Teams should indicate during online registration if they intend to qualify for the Toyota Fabrication and Manufacturing Award.

During the time between registration and the first race, approximately 8:00AM - 9:45AM, Judges will visit each qualified team and will conduct a 5 - 10 minute interview, focusing on the different manufacturing and fabrication techniques that were used in building the vehicle or vehicle system.

7.5 Race Awards (College)

Awards for 1st, 2nd and 3rd place are presented to the college teams having the highest total number of laps, scored over one of the 12 V heats and the 24 V race, as follows:

1st place will be awarded to the college team that completed the highest total number of laps according to the electronic scoring system.

2nd place will be awarded to the college team that completed the second highest total number of laps according to the electronic scoring system.

3rd place will be awarded to the college team that completed the third highest total number of laps according to the electronic scoring system.

7.6. Engineering Award (College)

The Engineering Award will be presented to the college team that demonstrates the best overall design innovation, use of engineering calculations, and design for ease of assembly, maintenance, ergonomics and safety in their competition vehicles. Teams will be judged based on in-person interviews as well as documentation for the car provided in advance, including mechanical drawings, electrical schematics and cost spread sheets.